DOM MODEL SERIAL NUMBER VOLTAGE/HERTZ/PHASE

Transcription

1 DOM MODEL SERIAL NUMBER VOLTAGE/HERTZ/PHASE

2 DON T JUST DO IT! Make sure the chiller you buy has been ETL listed as a complete unit. Intertek Testing Services, testing is your only assurance that your chiller is safe for your customers and employees. Water, electricity and people don t mix. Unfortunately, it is not against the law to build and sell chillers without third party laboratory testing. Help us to change the law, write your congressman, until the law is changed... DON T BUY AN UNSAFE CHILLER LOOK FOR THE WARNING SIGNS ETL label without the chiller manufacturer s name on it A Pump that is not approved for package systems CHILLERS that look poorly constructed Ask for the ETL listing numbers in writing CHECK THE LIST! CHECK IT TWICE! UNIT TESTED This chiller was tested under actual use conditions as a complete unit and listed by Intertek Testing Services

3 Aqua Products Company, Inc. uses only the highest quality components available in all of the equipment manufactured. However, control components do fail occasionally, therefore Aqua Products Company, Inc. highly recommends the use of propylene glycol in all of it s systems to prevent freeze damage to the evaporator coil should a malfunction occur. Please do not hesitate to call the service department at (800) if there are any questions regarding this recommendation. For more information on Dow brand glycol or for the dealer nearest you, please call (800) For more information on NuCalgon brand glycol, or for the dealer nearest you, please call (800) OR call Johnstone Supply in your area. *** Note: Automobile anti-freeze will cause serious damage to your chiller and will void your warranty!!! IMPORTANT - IMPORTANT - IMPORTANT DO NOT USE PIPE SIZE ANY SMALLER THAN WHAT IS RECOMMENDED IN THE HEADER SIZING CHART IN THIS MANUAL. DO NOT ELIMINATE THE BYPASS THROTTLING VALVE AS SHOWN ON THE PIPING SCHEMATIC IN THIS MANUAL. FAILURE TO FOLLOW THESE RECOMMENDATIONS WILL RESULT IN ERRATIC CHILLER OPERATION AND MAY VOID THE MANUFACTURERS WARRANTY. PLEASE READ THIS INSTALLATION MANUAL AL IN ITS ENTIRETY BEFORE INSTALLATION, INCLUDING THE PART REPLACEMENT WARRANTY PROCEDURE AS WELL AS THE LIMITED PARTS WARRANTY. READING THIS MANUAL WILL SAVE YOU TIME AND MONEY IN THE FUTURE!

4 NOTICE ALL CHILLERS PRODUCED BY AQUA PRODUCTS COMPANY, INC. COME WITH VENTED POLYETHYLENE TANKS. WE RECOMMEND THAT YOU DO NOT LEAVE WATER ON AFTER FILLING THESE TANKS. IF WATER IS LEFT ON THESE TANKS WILL OVER FLOW. CLOSED PRESSURIZED TANKS ARE AVAILABLE FOR MODELS THAT ARE NOT UTILIZING AN INTERNAL TANK.

5 DCS/DCP & WCS/WCP SERIES CHILLER Aqua Products Company, Inc. has made effort to obtain the highest quality parts in the manufacturing of their Chillers. The DCS & WCS series chiller is a complete packaged chiller with a separate tank and pump which may be purchased locally or from Aqua Products Company, Inc. The DCP & WCP series chiller is a complete packaged chiller with tank and pump built into one unit. The DCS/DCP series chiller incorporates air cooled condensing units; the WCS/WCP series chiller incorporates a water cooled condensing unit. STANDARD FEATURES: 1) Evaporator The evaporator is a helical wound tube in tube type heat exchanger. The outer tube or shell which the refrigerant passes through is made of steel. The inner tube which the water passes through is made of convoluted copper for maximum heat transfer. NOTE: Other materials are available for special applications such as CUPRONICKLE, STAINLESS STEEL and DOUBLE WALL VENTED POTABLE WATER 2) High Pressure Safety The high pressure safety shuts the unit off if refrigerant pressure exceeds 425 PSI. This safety will reset automatically. 3) Low Pressure Safety The low pressure safety shuts the unit off if refrigerant is lost or low. This safety will reset automatically. 4) Control Circuit The control circuit for all chillers is 24 VAC. 5) Flow Switch The flow switch shuts off the unit in a no flow or low water flow condition. 6) Low Ambient Fan Cycle Switch The Fan Cycle Switch cycles the condensing unit fan on and off to maintain head pressure. 7) Durable Cabinet The cabinet is constructed with 16 gauge aluminum that is primed and painted. 8) All units are Factory Tested to ensure trouble free installation. Please read this installation manual completely before beginning installation of the unit. Note the procedure to follow for parts replacement and warranty claims. Reading this manual now may save you time and money later. Aqua Products Co., Inc. takes pride in its workmanship and service. Should there be any questions regarding the Chiller or this installation manual, please do not hesitate to call our Service Department at (803)

6 INSTALLATION GUIDELINES This product must be installed and serviced by a qualified, licensed technician and must conform to all local and national codes. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. The following information is intended to assist this individual in a successful installation. LOCAL AND/OR NATIONAL CODES TAKE PRECEDENCE OVER THESE INSTALLATION INSTRUCTIONS. CAUTION: Single wall heat exchanger, not suitable for potable water applications. For potable water applications use only certified coils. Consult factory for specifications. Several conditions must be given when determining the location to install the chiller. They are as follows: 1) FOUNDATION OR FLOOR This must be strong and level for proper chiller operation. It is strongly recommended that a vibration absorption pad or like material be used since the normal vibration produced by the compressor may be amplified where the chiller cabinet meets its mountings if not insulated. 2) AIR CIRCULATION It is very important that the chiller has at least 3 feet of free space on all sides of the condensing coil and a minimum of 4 feet above the chiller where the exhaust air is discharged. No free space is required for water cooled (WCS/WCP series) chiller. 3) INDOOR VERSUS OUTDOOR INSTALLATION (FOR AIR-COOLED CHILLERS ONLY) If at all possible, air-cooled chillers should be placed outdoors. If this is not possible, it may be installed indoors if certain precautions are followed: a. Steps #1 and #2 above must be followed for air-cooled (DCS/DCP) chillers. b. The Chiller will produce large quantities of heated air in the water-cooling process. This heat must be removed from the building. In order to accomplish this, a ducted discharge should be used.!!!warning-never ATTACH ANY DUCT WORK TO THE CONDENSING UNIT!!! The fan on the condensing unit is not engineered to handle any static pressure. The ducted discharge must be constructed with its own ventilator fan to pull the heated air from the general area of the chiller. The ventilator must be sized so as not to starve the condenser of the cooling air it needs. (Consult your local distributor)

7 TABLE (2) HEADER SIZING CHART SUPPLY HEADER ALL CHILLERS RETURN HEADER ALL CHILLERS CONDENSING WATER WATER COOLED ONLY IN OUT 1.5 THRU 2.0 TON CHILLERS ¾ 1 ½ ½ 2.5 THRU 5 TON CHILLERS 1 1 ¼ ¾ ¾ 5 THRU 7.5 TON CHILLERS 1 ¼ 1 ½ TON CHILLERS 1 ½ 2 1 ¼ 1 ¼ 15 TON CHILLERS 2 ½ 3 1 ¼ 1 ¼ The header sizes in this chart are based on a maximum of 30 feet of header length and the standard pump furnished with each unit. Note: For multiple chillers, use total tonnage of units; i.e. (2) 5 ton chillers installed in parallel would equal a 10 ton load for header sizing purposing. Consult Factory, if needed. TABLE (3) MINIMUM WIRE SIZE CHART CHILLER MODEL 3 PHASE 1 PHASE WIRE SIZE DCS/DCP/WCS/WCP 2 #10 #10 DCS/DCP/WCS/WCP 3.5 #10 #10 DCS/DCP/WCS/WCP 5 #8 #10 DCS/DCP/WCS/WCP 6 #8 N/A DCS/DCP/WCS/WCP 7.5 #6 N/A DCS/DCP/WCS/WCP 10 #6 N/A ***3 phase voltage not available on DCS/DCP 2 Ton Models*** ***CHECK UNIT NAME PLATE FOR MINIMUM CIRCUIT AMPS TO DETERMINE EXACT MINIMUM WIRE SIZE***

8 PIPING SYSTEM The piping or header system is the most important installation procedure in this manual. If these recommendations are not followed, the Chiller may not operate properly. 1) Never reduce the water connections to the chiller. 2) Never reduce the pump suction. You may, however, reduce the pump discharge at the pump for DC/S 2 or DC/S 3 systems. 3) All pipe fittings and valves create restriction (head) on the system. It is very important to keep this restriction to a minimum. An easy way to do this is to use a few elbows as possible and to use 45 degree elbows. They create half the restriction of a 90 degree elbow. 4) When selecting valves, use gate valves one size larger than the pipe size. (Example: 1 pipe, 1 ¼ gate valve) The reason for this is the port or passage of most valves is one pipe size smaller than the valve. 5) Many machines have only one water inlet and one water outlet that feed two or more components on the machine. If this is the case on your machine, these lines should be removed and a separate return and supply line from the header system must be installed on each component requiring cool water. Do not use rubber hose or like materials to make these connections because they are very restrictive. Instead, use hard pipe to within one foot or less and make the final connection with an industrial grade vibration isolator-type hose. 6) It is very important that a by-pass valve be installed in the header system. (See Figures 1 & 2 for air-cooled units and Figures 1A & 2A for water-cooled units). This valve has two main purposes: a) Enables you to maintain a proper and constant back pressure on the system. b) Mixes chilled supply water with hot return water so that the chiller will not become overloaded. 7) If two or more chillers are used in one system, they must be piped in parallel, making sure to balance the flow to and from the chillers. (See Figure 1A & 2A & 3A for typical piping diagrams.)

9 NOTE #5 PUMP CHILLER NOTE #6 VENTED STORAGE TANK THESE ARE EXAMPLES OF HEAT LOADS YOUR HEAT LOADS MAY BE DIFFERENT. NOTE #2 NOTE #3 (PRESSURE GAUGE) IT IS RECOMMENDED THAT A PRESSURE GAUGE BE INSTALLED FOR QUICK REFERENCE WHEN SETTING UP SYSTEM AND FOR NORMAL SYSTEM MONITORING. (BYPASS VALVE) USED TO ENSURE PROPER WATER FLOW THROUGH CHILLERS WHEN LOADS SHUT DOWN. WE HIGHLY RECOMMEND AN AUTOMATIC TYPE SUCH AS A PRESSURE ACTIVATED VALVE. NOTE #4 ISOLATION AND CIRCUIT SETTING VALVE. NOTE #5 PUMP ISOLATION VALVES NOTE #6 (AIR COOLED DCS SHOWN) UNITS MAY BE EITHER AIR COOLED OR WATER COOLED. FIGURE 1A NOTE #4 FAN COIL AQUA PRODUCTS CO., INC. SINGLE DCS/WCS PIPING DIAGRAM AUGUST PIPING KEY CHILLER SUPPLY SUPPLY HEADER RETURN HEADER NOTE #3 PROCESS HEAT LOAD NOTE #2

10 NOTE #6 CHILLER WATER LEVEL SIGHT GLASS FRONT NOTE #5 MAKE UP WATER THESE ARE EXAMPLES OF HEAT LOADS YOUR HEAT LOADS MAY BE DIFFERENT. NOTE #2 NOTE #3 (PRESSURE GAUGE) IT IS RECOMMENDED THAT A PRESSURE GAUGE BE INSTALLED FOR QUICK REFERENCE WHEN SETTING UP SYSTEM AND FOR NORMAL SYSTEM MONITORING. (BYPASS VALVE) USED TO ENSURE PROPER WATER FLOW THROUGH CHILLERS WHEN LOADS SHUT DOWN. WE HIGHLY RECOMMEND AN AUTOMATIC TYPE SUCH AS A PRESSURE ACTIVATED VALVE. NOTE #4 ISOLATION AND CIRCUIT SETTING VALVE. NOTE #5 CHILLER ISOLATION VALVES NOTE #6 (AIR COOLED DCP SHOWN) UNITS MAY BE EITHER AIR COOLED OR WATER COOLED. NOTE #4 FIGURE 2A FAN COIL AQUA PRODUCTS CO., INC. DCP/WCP PIPING DIAGRAM SEPT PIPING KEY SUPPLY HEADER RETURN HEADER NOTE #3 PROCESS HEAT LOAD NOTE #2

11 CHILLER #1 CHILLER #2 NOTE #7 NOTE #7 NOTE #6 NOTE #5 FIGURE 3A PUMP VENTED STORAGE TANK THESE ARE EXAMPLES OF HEAT LOADS YOUR HEAT LOADS MAY BE DIFFERENT. NOTE #2 (PRESSURE GAUGE) IT IS RECOMMENDED THAT A PRESSURE GAUGE BE INSTALLED FOR QUICK REFERENCE WHEN SETTING UP SYSTEM AND FOR NORMAL SYSTEM MONITORING. NOTE #3 (BYPASS VALVE) USED TO ENSURE PROPER WATER FLOW THROUGH CHILLERS WHEN LOADS SHUT DOWN. WE HIGHLY RECOMMEND AN AUTOMATIC TYPE SUCH AS A PRESSURE ACTIVATED VALVE. NOTE #4 ISOLATION AND CIRCUIT SETTING VALVE. NOTE #5 PUMP ISOLATION VALVES NOTE #6 ENSURE PIPING IS OF EQUAL LENGTH GOING TO EACH CHILLER WHEN PIPING MULTIPLE UNITS TOGETHER IN PARALLEL ALL UNITS MUST BE PIPED IN PARALLEL. NOTE #7 (AIR COOLED DCS SHOWN ) UNITS MAY BE EITHER AIR COOLED OR WATER COOLED. NOTE #4 AQUA PRODUCTS CO., INC. MULTIPLE DCS/WCS PIPING DIAGRAM AUGUST PIPING KEY CHILLER SUPPLY SUPPLY HEADER RETURN HEADER NOTE #3 PROCESS HEAT LOAD NOTE #2

12 TROUBLE SHOOTING FLOW CHART FOR DCS/DCP CHILLERS This flow chart assumes main power is applied, water is flowing and control circuit switch is on. Note #1 Delete phase monitor checks for single phase machines and 3 phase machines without phase monitors. Note #2: If there is no display on temperature controller the flow switch is either faulty or there is not enough flow to actuate it. Chiller won't start Note #1 Check for green light on phase monitor Red Remove power and swap main power leads L1 and L3 reapply power Green Check for green light on phase monitor END Yes Did chiller start No Red Remove power check all connections reapply power. If no green light call factory. Note #2 Check that temp. controller is set up properly and that there is an output signal on the NO terminal. Fl owchart Key Start/End Yes Did chiller start Action No Decision Reset high pressure switch Flow Direction Yes Did chiller start No Call factory

13 Correct Pump Installation For Vented Or Open Tanks Discharge Suction This installation shows the pump with a flooded suction, which means water is available at the suction port of the pump at all times. You can see by this diagram that the water is being gravity feed to the suction end of the pump from the bottom of the tank. The tank can be higher than the pump but never lower. Incorrect Pump Installation For Vented Or Open Tanks Discharge Suction This installation shows the pump without a flooded suction, which means water is not available at the suction port of the pump at all times. You can see by this diagram that the pump must try to draw the water up from the tank, but the pump is not designed to do this so damage to the pump will occur from the pump running dry. The tank can be higher than the pump but never lower.

14 ELECTRICAL Consult the front page of this manual for electrical data as it pertains to your chiller. All installations must be performed by a qualified, licensed technician and must conform to all local and national codes. 1) Use circuit breakers. The use of fuses only on a three phase system may cause single phasing and burn out the compressor. 2) All field applied wiring must comply with local and national codes, but must be at least the sizes indicated in Table 3. 3) All field connections to the chiller must be made to L1, L2, and L3 main terminals of the compressor contactor. 4) There is a machine ground lug provided. These must be hooked up to avoid personal shock or injury. 5) All control circuit wiring is 24 VAC. 6) For units with a crankcase heater, ensure power is left on to the unit at all times after the installation is complete.!!!if STEP 6 IS NOT FOLLOWED, THERE WILL BE COMPRESSOR DAMAGE!!! Controls, Safety Devices and Their Features 1) High Pressure Safety- The high-pressure safety will shut the unit off if pressure exceeds 425 psi. This will automatically reset. If the safety trips, it should be checked by a qualified technician. 2) Low Pressure Safety- The low-pressure safety protects the compressor from overheating if the refrigerant charge is lost or less than 10 PSI. This will automatically reset. This device opens at 10 PSI and automatically resets at 25 PSI. If the unit appears to be short-cycling, it should be checked by a qualified technician. 3) Low Ambient Fan Cycle Switch- The Fan Cycle Switch cycles the condensing unit fan on and off to maintain the systems head pressure for proper operation below 60 degrees F. 4) Flow Switch- The flow switch shuts the unit off in a no flow or low water flow condition to prevent the evaporator from freezing.

15 WATER TREATMENT!!!DO NOT USE ANTI-FREEZE IN GALVANIZED PIPE SYSTEMS!!! Precautions against system freezing and fouling must be taken to ensure trouble free operation. To accomplish this we suggest several brands of anti-freeze. Not only does glycol protect against freeze up, but it also incorporates an additive package, which contains corrosion, suspension, and anti-foaming agents. The brands we recommend are Dow frost, a propylene glycol based anti-freeze, pipe saver, and NuCalgon. Note: NuCalgon has additives recommended for our systems. If the Chiller is to be installed on an already existing system, it is recommended that the system be cleaned out with a trisodium phosphate (TSP) solution prior to installing the anti-freeze and to flush the system thoroughly with fresh water. Never use less than 30% of glycol mixture since you need at least this amount in order for the corrosion inhibitors to do their job. Nor should you use more than 60% since glycol's become aggressive above this concentration. Remember, this is a one-time investment for years so please make every effort possible to properly install the glycol the first time so you won t be disappointed in the future. FREEZE PROTECTION CHART % Anti-freeze Freezing temperature % water by volume (Degrees f) by volume Do not use glycol concentrations greater than 60% or less than 30%. For more information on DOW Brand anti-freeze call: Nu Calgon call: For more information on Pipe Saver anti-freeze call: Virginia KMP Corporation call: ***NOTE: AUTOMOBILE ANTI-FREEZE WILL CAUSE SERIOUS DAMAGE TO YOUR CHILLER AND VOID YOUR WARRANTY!!!***

16 APCI Limited Warranty Aqua Products Company, Inc. (APCI) warrants this product to be free from defects in factory workmanship and material under normal use and service and will, at it s option repair or replace parts proved to have such defects for a period of (1) year. Time period is measured from the date of installation or, if such date is not determinable, from the date of shipment of the product from the APCI factory. For your benefit and protection, return the warranty registration card to APCI promptly after installation. This will initiate the warranty period and allow us to contact you, should it become necessary. In the absence of a recorded Warranty Registration Card, the warranty period will begin upon product shipment form APCI. This Warranty extends only to the original consumer purchaser and is non-transferable. For this warranty to apply, the product must be installed according to APCI recommendations and specifications, and in accordance with local, state and national codes, and product must not be removed from it s place of original installation. The warranty period for repair or replacement parts provided hereunder shall not extend beyond the warranty period stated above. This warranty applies only to products installed in the United States and Canada. EXCLUSIONS 1. Shipping, labor, glycol, refrigerant, truck time or material charges. 2. Damages resulting from transportation, installation, or servicing. 3. Damages resulting from accident, abuse, fire, flood, alteration, or acts of god. Tampering, altering, defacing or removing the product serial number tag will serve to void this warranty. 4. Damages resulting from use of the product in a corrosive atmosphere. 5. Damages resulting from inadequacy or interruption of electrical service, improper voltage conditions, blown fuses, or other like damages. 6. Damages resulting from freezing. 7. Damages resulting from operation with inadequate supply of air or water. 8. Damages resulting from use of components or accessories not approved by APCI. This warranty is in lieu of all other warranties, express or implied, including the implied warranties of merchantability and fitness for a particular purpose. Some states do not allow the disclaimer of implied warranty, so that the above disclaimer may not apply to you. Some states allow only partial limitation on implied warranties to limit the duration of implied warranties to the duration of the express warranty. In such states, the duration of implied warranties is hereby expressly limited to the duration of the express warranty on the face hereof. In no event, whether as a result of breach of warranty or contract, tort (including negligence) strict liability or otherwise, shall APCI be liable for special, incidental, or consequential damages, including but not limited to loss of use of the equipment or associated equipment, lost revenues or profits, cost of substitute equipment or cost of fuel or electricity. The above limitations shall inure to the benefit of APCI supplies and subcontractors. The above limitation on consequential damages shall not apply to injuries to persons in the case of consumer goods. Some states do not allow the exclusion or limitation of liability for consequential or incidental damages, or for strict liability tort, so that the above exclusions and limitations may not apply to you. APCI does not assume, or authorize any other person to assume for APCI and other liability for the sale of this product. This warranty gives you specific legal rights you may also have other rights which vary form state to state. TO OBTAIN WARRANTY SERVICE Notify your installing or servicing dealer, preferable in writing, of the problem as soon as possible after its discovery. Be sure to include product model number, serial number, installation date and the nature of the problem. If a response is not received within a reasonable time notify APCI at P.O. Box 39 Prosperity, SC USA. Service requests sent to APCI without prior dealer contact will be referred back to dealer. For Owners Information Product Model No. Installation Date Unit Serial No. Installing Dealer